The successful delivery of the largest rigid pavement ...

Woolgoolga to Ballina Pacific Highway upgrade

The successful delivery of the largest rigidpavement program undertaken by TfNSW (nee RMS)

ASCP Forum | 14th July 2020


Woolgoolga to BallinaMichael Heathwood

Pavements Lead | Pacific Complete

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Woolgoolga to Ballina

• The Project• The Delivery Partner• Strategies for Success• Quality of Product


The Project

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Woolgoolga to BallinaPacific Highway upgrade



Final link

Our legacy

Delivery partner model



155km dual carriagewayhighway

170 bridges Nine interchanges

Bypasses 5 towns 14.2 million cubic metres ofearthwork

About 3,500 peakemployment


Scope

• 78% of the mainline is rigid pavement (PCP)

• Standard RMS embankment with 150mm LCS and 250mm PCP

Portion of work LMC + PCP (m3)

A – Glenugie to Maclean 310,000

C – Maclean to Richmond River 360,000

D – Richmond River to Ballina Bypass 80,000


The Delivery Partner


Pacific Complete

Our goal: “driven to save lives”

As Australia’s first delivery partner,we are working with stakeholders atan unprecedented scale and pace tosuccessfully deliver the final link in thePacific Highway upgrade. This is ourlegacy.

… Pacific Complete Programme Leadership Team


Pacific Complete

• Pacific Complete - Who is it? What is it? Why?

Packaging &Procurement

Cost Plan

ProjectManagement

DeliverySchedule


Strategies for success

- Materials Supply Agreements

- Laboratory establishment- Concrete Mix consistency


Strategies employed for Success

Materials Supply Agreements – Quarries

Laboratory establishment

Concrete Mix consistency


Materials Supply Agreements - Quarries

Executed through supply deeds

Dedicated resources

Made and stockpiled ahead ofschedule

DA approvals for movementsadequate to meet demand

Quality of materials

Contractor to manage


Laboratory establishment

Portion Wide Laboratory Establishment

All contractors in that Portion usedthat specific laboratory for testing

List of tests and cost per testprocured separately

Challenges

Different approach to “PrimaryTesting”

Clear definitions required aroundtesting involved in each specification


Concrete mix consistency

Pacific Complete conducted 22 trial mixesduring the course of the project

Focus on minimizing the drying shrinkage

Workability, coarseness, gradingcharacteristics Slip-formability?

Box testing and Kelly Ball testing wasadditionally done

Results of the trials confirmed theaggregates selected during the MSAprocurement would be suitable for use

Subject to mix designs being conducted bythe Contractors to suit the individualequipment


Quality of Product- Production Numbers- Ride- Bridge deck pavement


Program completion

• The construction program is 85%complete

95% earthworks complete

92% Concrete pavements complete

• There is in the order of:

60,000 WAE drawings

650,000 documents to betransmitted

274 Property Adjustment plans

• Asset transfer workshops planned 48


Production Numbers – Concrete pavement


Ride

The ride testing data is showing that across the program the contractorsare all achieving outcomes of between 20-35 NAASRA bump countsand only small areas of base concrete being diamond ground foradverse ride or poor surface texture finish following ‘imminent’ rain …

W2B has excellent riding quality


Bridge deck pavements

Innovation through design phase

• Apply R93 to bridge decks …

• Needed to develop ‘specific’ bridge drawings

• 9 twin bridges diamond ground with Conventional Diamond Grinding

• Excellent results, especially for ride.



Apply R93 to bridge decks … but …must develop ‘specific’ bridge drawings



Apply R93 to bridge decks … but …must develop ‘specific’ bridge drawings




Thanks – Q’s & maybe A’s?

The successful delivery of the largest rigid pavement ...

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